Rockford Manufacturing Group Inc.

Single Source for Wire Payoff ● Descaling ● Wire Drawing ● Straightening & Cutting ● Recoiling

RMG In-Line Wire Drawers

In 2003 Rockford Manufacturing Group acquired the Fastener Engineers. These two companies, pioneers and leaders in In Line Wire Drawing, now combined have over 80 years of experience designing, building and innovating in line drawers and related equipment. We have taken advantage of the joining of our companies to combine the best technologies and experiences of both engineering groups to develop one distinct brand of In-Line Wire Drawers under the RMG name.

In-line wire drawing is the very definition of Lean and Green Manufacturing, by processing the wire as it is consumed, without generating material waste. We developed Variable Frequency Drive's to replace the less efficient hydraulic drive units. The new VF powered RMG wire drawers use 50% less electrical power compared to older Fastener Engineers or RMG hydraulic wire drawers. These electrical savings can also be achieved by retrofitting hydraulic drive units with the newer RMG drive technology.

- Catalog Information -

200
500
56-78
89
910-1011
1112-1416
1922
SpaceSaver's
Benefits

The All New Model 200

Model 200Introducing the Model 200 Micro Drawer, RMG’s newest and smallest inline wire drawer.

The Model 200 is another modern machine in RMG's new global line of in-line wire drawers, designed specifically to meet the ever demanding needs of global high technology manufacturers using micro formers and specialty metals. The 200 designation refers to the 10" (254 mm) nominal diameter of the hardened D2 capstan, a vital feature of every RMG inline drawer. We've kept the best and added new innovations, technology and materials where they will increase the utility, efficiency and performance of the inline drawer.

The maximum wire diameter for Model 200 with mild steel is .13" (3.2 mm) and 0.10" (2.5 mm) for typical steel alloy wire. The Model 200 can create tractive, or draw forces of up to 1500 lbs (1800kg) and speeds up to 100 fpm (30.5 mpm) are available, sufficient to achieve deep draws in a variety of materials. Contact the factory for complete specifications and capabilities in specific applications.

The footprint of this machine is 22" X 30" (560 mm X 760 mm)and at 640 lbs (1400 kgs) it packs in all the necessary features and few new surprises. A new integral gripper, eliminating the need for and complexity of a gripper chain, has been designed into the capstan. In addition, the pointer box and draw box have been redesigned to simplify and speed up coil loading and changeover. Pull just one pin to switch the boxes out.

To correctly size and configure the new Model 200 micro inline wire drawer for your operation please contact your Independent RMG sales representative or contact RMG directly. We will ask you for some specific information; wire size, tensile strength and material type, max./min. wire feed rate, wire-line height, beginning and ending wire diameters, etc. to start the process of designing and building the best machine for your application. All our machines are built to order, so we can insure you get the optimum machine for your application and process.

Model 500

Model 500The Model 500 is the first in RMG's new line of global design in-line wire drawers. The 500 designation refers to the 20" (500 mm) nominal diameter of the hardened D2 capstan that is a vital feature of every RMG inline drawer. We've kept the best and added new innovations, technology and materials where they will increase the utility, efficiency and performance of the inline drawer.

The maximum wire diameter for Model 500 with mild steel is 0.312" (8.0 mm) and 0.250" (6.4mm) for typical steel alloy. Tractive, or draw forces of 4000 lbs (1800kg) and speeds up to 130 fpm (40 mpm) are available. Contact the factory for other materials.

The many advantages of in-line wire drawing are well understood and accepted by leading companies around the world. RMG has embarked to create a line of machines that natively meet all specified and implied usage standards. Gone are the days of one machine designed for the domestic or US markets, and another uniquely configured for Europe and other markets. Multinational companies can procure one machine model to place in their facilities anywhere in the world. Components are globally sourced allowing operators greater latitude to maintain and repair their machines using local sources and familiar metric tools.

The only model distinctions will be those of necessity; local voltage requirements, specific applications requirements (wire line height, speed, tractive force, etc.) and customer requested options suited to their unique production situations (liquid draw boxes, pendant/remote controls, lifting provisions, etc.).

To correctly size and configure an inline wire drawer for your operation please contact your Independent RMG sales representative or RMG directly. We will ask you for some specific information; wire size, tensile strength and material type, max./min. wire feed rate, production machine to be supplied with drawn wire, etc. to start the process of insuring we select the best machine for your application.

Model 56 through 78

Model 56

These are the inline wire drawing workhouses of many wire industries. With mild steel wire diameter capacities up to 0.500" (12.7 mm) these machines are typically coupled with cold headers and boltmakers or with high-speed straighten and cut machines. With nominal diameters of 24" (600 mm) and 28" (700 mm), the through hardened and polished D2 capstans of these machines provide many years of no maintenance operation.

To correctly size and configure an inline wire drawer for your operation please contact your Independent RMG sales representative or RMG directly. We will ask you for some specific application information; wire size, tensile strength and material type, max./min. wire feed rate, production machine to be supplied with drawn wire, etc. to start the process of insuring we create the best machine for your operation.

Interesting Tidbit The true diameter of the drawer capstan was originally chosen to yield an easily calculated linear wire speed, not a standard diameter as some "Johnny-come-lately" to in-line drawing have implied. A nominal 20" (508 mm) capstan is actually 19.09" (485 mm) in diameter. Thus a 20" (508 mm) RMG drawer actually produced 5' (1524 mm) of wire for every capstan revolution (C= π D). A 24" (610 mm) RMG machine produced 6' (1829 mm) of wire, a 28" (711 mm) capstan produced 7' (2134 mm), and so on. These convenient diameters were chosen in the days before computers and CAD when we did most calculations longhand and with sliderules, so we chose numbers we could easily compute.

Model 89

Model 89

These are the inline wire drawing workhouses of many wire industries. With mild steel wire diameter capacities to 0.562" (14.2 mm) these machines are typically coupled with larger cold headers and boltmakers or with high-speed straighten and cut machines. Designed around a nominal diameter 36" (900 mm), through hardened and polished D2 capstan these machines will provide many years of no maintenance operation.

To correctly size and configure an inline wire drawer for your operation please contact your Independent RMG sales representative or RMG directly. We will ask you for some specific application information; wire size, tensile strength and material type, max./min. wire feed rate, production machine to be supplied with drawn wire, etc. to start the process of insuring we create the best machine for your operation.

Model 910 through 1011

Model 910

The Model 910 and the Model 1011 use 36" (900 mm) and 44" (1100 mm) nominal diameter capstans respectively. Capable of generating tractive forces of over 16,000 lbs (7260 kg) these drawers can achieve heavy diameter reductions up to 0.700" (18 mm) mild steel at speeds up to 107 fpm (33 mpm). Both units are ideal for the new generation of high speed .500" (13mm) - .688" (17.5 mm) cold formers and headers, providing precisely calibrated wire for the high quality parts required.

Each can be configured with specific options, such as powered feed head w/pre-straightener, pendant controls, multiple draw box arrangements, dual relaxer rolls, pneumatic wire containment rolls at seven o'clock, and/or twelve o'clock positions, 2-plane straighteners, etc. to accommodate every process and manufacturing environment. The heavy duty by-fold door allows full access to the capstan during coil changeover yet fully contains the wire and prevents interference during normal operation.

Model 1214 through 1416

Model 1416

The Model 1214 and the Model 1416 are the big boys of RMG's inline wire drawer product line. Using 44" and 52" inch through hardened tool steel (D2) capstans, efficient VF electric motors and extremely rugged high-torque gearboxes, these workhorses can generate 20,000 lbs (9060 kg) and 25,000 lbs (11,325 kg) of reliable tractive force. These drawers can achieve heavy diameter reductions on mild steel wire from 0.688" (17.5mm) to 1.00" (25.4 mm). Both units are ideal for the new generation of high quality cold formers and headers, providing precisely calibrated wire for the high quality blanks required. Each machine includes as standard equipment dual or quad pneumatic relaxer rollers, twelve o'clock roller, and a power-driven feed head assembly to feed and pre-straighten material during set-up.

Each can be configured for specific operations with many options, such as electronic end-of-coil detection, pendant controls, multiple draw box arrangements, wire containment rolls at seven o'clock, 2-plane straighteners, etc. to accommodate every process and manufacturing environment. The heavy duty by- or tri-fold door allows full access to the capstan during coil changeover yet fully contains the wire and prevents interference during normal operation.

Model 1922

Model 1922

Introduced just a few years ago, RMG has already placed into service around the world numerous examples of our largest In-Line Wire Drawer, the Model 1922 with a 5' (1500 mm) tool steel capstan. this 14' high (4270 mm), 12,000 lb (5443 kg) behemoth can accomplish deep draws at high speed on materials up to 1.375" (35 mm) in diameter. Incorporating VF technology, digital controls and every labor saving device at our disposal this rugged machine is nearly as easy to operate as our 0.700" (18 mm) in line drawers. All Model 1922's are custom designed and built to match the exacting requirements of the very latest in extra large capacity cold formers.

SpaceSaver's In-Line Wire Drawers

Model 56 SpaceSaver w/ Powered TurnTable

RMG created and introduced the patented SpaceSaver's inline wire drawer configuration in response to customer's needs for a compact, self-contained in-line wire drawing system. While many manufacturers of fasteners, ball bearings, wire products, etc., recognized the advantages and the value of in line wire drawing, some simply did not have the floor space available for the traditional in line drawer and payoff (turntable) set-up. With a SpaceSaver inline drawer, available from RMG for mild steel wire sizes from less than 0.125"(3.2mm) to 0.625"(14.2mm), the whole system can be essentially placed within the footprint of a typical inline wire drawer. With smaller wire sizes the wire coil turntable is placed atop the machine, for larger diameter, high tensile wire applications, the coil is at floor level within the frame of the machine. Coil loading is easily achieved with a forklift truck or an overhead crane system. Additionally, the wire is more easily contained during operation, enhancing operator safety.

Model 67 SpaceSaver




Contact your RMG sales representative or RMG's application engineers to determine how a SpaceSaver in line wire drawer can reduce cost, improve quality and increase your productivity without consuming valuable factory floor real estate.





Benefits and Advantages of RMG In Line Wire Drawing

In-Line Wire Drawing provides numerous benefits for fastener and wire products industries, listed below are a few of them.

  • Lower Material Costs - Using hot-rolled rod (for any wire diameter .218" (5.5 mm) and larger) and/or semi-finished wire versus bright basic will give your company a competitive edge and improve profits.
  • Utilize Just-In-Time Inventory - An in-line wire drawer at the point of wire consumption is the ultimate in JIT inventory management. By careful selection of parent diameters and drawing many different sizes from a few stock sizes, inventory dollars can be reduced considerably.
  • Provide Exact Diameter Control - An in-line wire drawer provides the perfect diameter at the point of use, consistently, eliminating any coil-to-coil variation. Consistent volume control depends upon exact diameter control.
  • Improve Metal Formability - Freshly drawn wire is easier to form and the heat generated by the drawing process improves the cold forming process. Many difficult cold-headed specials cannot be produced without utilizing a wire drawer.
  • Improve Tooling Life - Parts produced using freshly drawn wire require less forming force, thereby improving tooling life. In addition, consistent volume control means consistent heading tonnage which, in turn, consumes fewer tools.
  • Improved Wire Surface Conditions - The surface of wire drawn in-line has no chance to oxidize or deteriorate. Additionally, you control the quality, type and amount of wire lubricant in your own production process.
  • Eliminate Short Feeds Before They Occur - RMG's AUTODRAW Speed Control System matches the consumption rate of the production machine. All tension is removed from the feed rolls. Also, STARTGARD, SLIPGARD and TANGLEGARD sense any problem with the process and stop the production machine before a shortfeed occurs.
  • Eliminate Wire Kinks - Wire drawn in-line is always smooth and straight with a natural cast and with no kinks.
  • Employ any Coil Size or Weight - An RMG wire drawer does all the work of turning the coil and unwrapping the wire thereby eliminating the load on the feed rolls, regardless of coil size.
  • Increase Overall Performance - When you consider the improvements associated with an RMG machine; reduced material cost, improved tool usage, faster coil change time, fewer short feeds, better volume control and the ability to use ever larger coils, it's easy to understand why a header line utilizing an RMG in-line wire drawer will consistently outperform a header line that doesn't in both cost and consistency of product.
  • Lower material costs – Descaling hot rolled rod, or drawing semi-finished wire in-line, will drastically reduce your material costs, therefore improving profits and giving your company a competitive edge.
  • Reduced Pull Back on Feed Rolls – RMG’s AUTODRAW Speed Control System matches the consumption rate of the production machine. All tension is removed from the feed rolls. Also, STARTGARD, SLIPGARD and TANGLEGARD sense many problems with the process and immediately stop the production machine.

RMG offers complete OEM support for all Fastener Engineers models including authorized FE Tooling, Parts, Service and Technical information.

Rockford Manufacturing Group Lewis Machine Fastener Engineers

Contact us and we will help you to reduce your operating cost, increase your production output and improve your quality by designing and building a machine or production system to specifically meet your unique operational needs.